Profile element pipe for hydraulic bulging, hydraulic bulging device using the element pipe, hydraulic bulging method using the element pipe, and hydraulically bulged product

ABSTRACT

A profile element pipe for hydraulic bulging of the present invention has a peripheral length with an outer diameter gradually increasing or decreasing from one axial side toward the other thereof and has a parallel part formed on at least one end thereof. According to a bulging device and a bulging method using this profile element pipe, for example, even when a profile steel pipe having a cross sectional shape varying in the axial direction as in a tapered pipe is hydraulically bulged, a bulging in which an internal pressure loading and an shaft pressing are combined with each other can be performed to provide a larger expansion ratio than a conventional case and a joining and socket connection thereof to the other part can also be easily performed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a profile element pipe for hydraulicbulging, a hydraulic bulging device using the profile element pipe, ahydraulic bulging method using the profile element pipe, and ahydraulically bulged product subjected to the hydraulic bulging.

2. Description of the Related Art

A hydraulic bulging has more merits as compared with other forming orforming methods. For example, since a profile element pipe can behydraulically bulged to such an intricate configuration part havingdifferent cross-sections in the longitudinal direction of the product,machine parts, which require welding and joining in a conventionalmethod, can be formed in one-piece. Further, since the hydraulic bulginggenerates work hardening over the entire hydraulically bulged portions,even if a soft element pipe is used, a product having high strength canbe obtained.

Further, in the hydraulic bulging, the bulged product has smallspringback and a dimensional accuracy of the product is excellent (shapefreeze properties are excellent). Thus a process for refining productdimension is not required and the omission of the process is effected.

In the hydraulic bulging, the above-mentioned excellent merits areappreciated and the hydraulic bulging has been particularly adopted as aproduction method of automotive parts in recent years.

Generally, in case that a pipe is formed by hydraulic bulging, astraight pipe having a uniform circular cross-section in thelongitudinal direction of the pipe (hereinafter referred to as “straightelement pipe”) is used as a material, and after this material wassubjected to bending and crushing as a “pre-forming” hydraulic bulgingis performed as a final working process. By taking such a series ofworking processes, a hydraulically bulged product can be manufactured byprocessing a straight element pipe to a product of a predeterminedconfiguration.

FIGS. 1A and 1B are views showing a final working process of hydraulicbulging by which a product is obtained by using a conventional straightelement pipe. As shown in FIGS. 1A and 1B, in the hydraulic bulging ofthe final process, a working liquid is injected into a straight elementpipe P1 set in an upper die 1 and a lower die 2 through a filling hole 3to load internal pressure. Further, in addition to the loading ofinternal pressure, the element pipe P1 is axially pressed (hereinafterreferred to as “shaft pressing”) from both ends of the pipe by shaftpushing tools 4 and 5 also serving as sealing tools.

In the hydraulic bulging, the loading of internal pressure and the shaftpressing are combined with each other so that a product P2 havingvarious cross-sectional shapes is produced. It is noted that the shaftpushing tools 4 and 5 serving also as sealing tools are connected to ahydraulic cylinder (not shown) and during hydraulic bulging its axialposition or shaft pressing force are controlled.

The shaft pressing from a pipe end in the axial direction in thehydraulic bulging has such effects that a metal flow during bulging ofan element pipe is promoted and an expansion limit of the element pipeis improved. Thus, in the hydraulic bulging, the shaft pressing from thepipe end is an extremely important working process.

Specifically, when the hydraulic bulging is performed only by theloading of internal pressure without performing shaft pressing, the wallthickness of the straight element pipe P1 is remarkably decreased withbulging of the straight element pipe P1. Therefore, the straight elementpipe P1 ends up in rupture halfway through hydraulic bulging. Namely, itamounts to narrow a formable range (pipe expansion limit) of thestraight element pipe P1.

Further, the hydraulic bulging has a problem attributable to a shape ofthe element pipe. As described above, even if an intricate configurationhaving different axial cross-sectional shapes can be obtained as one ofthe merits of the hydraulic bulging, the configuration of a workedproduct which can be obtained is limited.

For example, when the relationship of the increase ratio in a peripherallength (pipe expansion ratio)=[(outer peripheral length of a workedproduct at the portion/circumferential length of element pipe)−1]×100%is defined, the limit of increase ratio in a peripheral length (pipeexpansion ratio) is at most 25% or so except for a region of the pipeend portion where shaft pressing is effective, although the ratiodepends on shape properties required for a bulged product or conditions(material, sheet thickness) of an element pipe to be used.

The hydraulic bulging cannot be performed beyond the limit of theincrease ratio in the peripheral length (pipe expansion ratio). Toincrease a degree of freedom in a configuration design of a workedproduct and to obtain a worked product having a more intricatecross-sectional shape, it is necessary to contrive ways regarding theshape of an element pipe under a restricted condition of such anincrease ratio in a peripheral length (pipe expansion ratio).

To deal with this problem, there has been proposed to use asubstantially conical element pipe (hereinafter referred to as “taperedelement pipe”) instead of a straight element pipe. Namely, by using thetapered element pipe, the increase ratio in a peripheral length due toworking can be suppressed to a low level for parts which are difficultto be formed by using a straight element pipe, for example, for partswhose peripheral length varies in the axial direction, thereby enablingpredetermined working shapes to be formed (see for example, JapanesePatent Application Publication No. 2001-321842, page 1, FIG. 2).

However, when hydraulic bulging is performed by using a tapered elementpipe whose cross-sectional shape varies in the axial direction, in caseof using a shaft pressing tool for the straight element pipe shown inFIG. 1, it is found difficult to apply the shaft pressing on the taperedelement pipe.

FIG. 2 is a view explaining a problem, which arises when shaft pressingwith a conventional shaft-pressing tool for a straight element pipe wasapplied on a tapered element pipe. As shown in FIG. 2, the shaftpressing itself on a tapered element pipe TP1 cannot be applied on thelarge diameter side, although the shaft pressing itself on the taperedelement pipe TP1 can be applied on the small diameter side. However, asa shaft pressing tool 4 advances into forms 1 and 2 with the shaftpressing, insufficient restriction of inner and outer surfaces of thetapered element pipe TP1 by the shaft pressing tool 4 side take places,thus likely leading up to seal leakage occurs.

FIGS. 3A to 3C are views explaining hydraulic bulging process using aconventional tapered element pipe, where FIG. 3A shows a state beforeprocessing, FIG. 3B shows a state before loading internal pressure, andFIG. 3C shows a state at the finish of processing.

In the conventional hydraulic bulging using the tapered element pipeTP1, as shown in FIGS. 3A to 3C, shaft pressing tools 6 and 7, eachhaving a tapered front end, are to be used. However, since shaftpressing cannot be performed, hydraulic bulging is generally completedonly by loading internal pressure without shaft pressing. It is notedthat TP2 in FIGS. 3A to 3C denotes a tapered element pipe subsequent topipe-end pre-forming and TP3 denotes a hydraulically bulged product.

In the working process shown in FIGS. 3A to 3C, since the shaft pressingof the tapered element pipe TP2 cannot be performed, the hydraulicbulging can be performed only in a limited range of forming to such adegree that rupture does not occur in a stage of hydraulic bulging, asdescribed above. Therefore, in the hydraulic bulging, a merit of usingthe tapered element pipe is not in fact fully utilized.

Thus, in case where hydraulic bulging is performed using a taperedelement pipe, a technological development, which enables shaft pressingfrom the pipe end in the axial direction in addition to loading internalpressure on the element pipe, has been desired.

When hydraulic bulging is performed in a conventional tapered elementpipe, there is a problem which arises when a hydraulically bulgedproduct is joined with another member, other than the problem that shaftpressing is difficult.

FIGS. 4A to 4C are views explaining a problem when a hydraulicallybulged product having a rectangular cross-section is joined, whereinFIG. 4A shows a shape of a conventional hydraulically bulged product,and FIG. 4B shows a shape of a hydraulically bulged product according tothe present invention, along with denoting inclinations of pipe endportions with respect to the axial direction of each worked product, andwherein FIG. 4C shows a configuration of a typical cross-section of thehydraulically bulged products in FIG. 4A or 4B.

The hydraulically bulged product PT3 using a conventional taperedelement pipe as a material is inclined in the pipe end portions by θ asshown in FIG. 4A. Thus, since accuracy cannot be ensured in welding andjoining with another member, the joining with another member or the likeis not easy.

Further, when an end of the pipe is socketed into another part andconnected thereto, that is a socket connection, the accuracy cannot beensured as well. Thus positioning of the tapered element pipe becomesdifficult. Consequently, finishing process such as cutting off of veryends of hydraulically bulged product is required.

SUMMARY OF THE INVENTION

The present invention has been made taking the above-mentionedconventional problems into consideration, and the object of the presentinvention is to provide a profile element pipe for hydraulic bulging, ahydraulic bulging device using the element pipe, a hydraulic bulgingmethod using the element pipe, and hydraulically bulged product, whereinin hydraulic bulging using the profile element pipe having various crosssectional shapes in the axial direction, shaft pressing is enabled fromthe pipe ends in the axial direction in addition to loading internalpressure on the element pipe, thereby enabling a larger pipe expansionratio to be achieved.

To attain the above-mentioned object, a profile element pipe forhydraulic bulging according to the present invention is characterized inthat the profile element pipe has a varied peripheral length over theaxial length with an outer diameter gradually increasing or decreasingfrom one axial side toward the other thereof and has a parallel partformed on at least one pipe end thereof.

In the profile element pipe for hydraulic bulging of the presentinvention, a length of the parallel part is preferably not less than thetotal of an amount of shaft pressing performed in the hydraulic bulgingand a length necessary for sealing during bulging.

Further, in the profile element pipe to be used for manufacturing ahydraulically bulged product having a rectangular cross section or apolygonal cross section, it is desirable that a radius R of curvature ofa corner part in the parallel part is varied in accordance with a changeof a peripheral length in which an outer diameter of the profile elementpipe is gradually increased or decreased.

And if the profile element pipe of the present invention comprising sucha configuration is set into a form of a hydraulic bulging deviceaccording to the present invention by respectively providing parallelparts on at least one of end portion inner surfaces of both an upper dieand a lower die and on an outer surface of a shaft pressing tool whichmatches with pipe-end inner surfaces, an internal pressure loading and ashaft pressing in combined manner can be applied.

As described above, in the hydraulic bulging, a larger pipe expansionratio can be obtained than before, and the joining with other parts canbe easily performed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are views explaining a final process in hydraulicbulging process by which a product is obtained by using a conventionalstraight element pipe.

FIG. 2 is a view explaining a problem, which arises when shaft pressingof a tapered element pipe is performed with a conventionalshaft-pressing tool for a straight element pipe.

FIGS. 3A to 3C are views explaining hydraulic bulging processes using aconventional tapered element pipe, where FIG. 3A shows a state beforebulging, FIG. 3B shows a state before loading internal pressure, andFIG. 3C shows a state at the end of bulging.

FIGS. 4A to 4C are views explaining a problem which is generated when ahydraulically bulged product having a rectangular cross-section isjoined, where FIG. 4A shows a shape of a hydraulically bulged productusing a conventional tapered element pipe, FIG. 4B shows a shape of ahydraulically bulged product according to the present invention, andFIG. 4C shows a shape of a cross-section of these products.

FIGS. 5A and 5B are cross-sectional views showing an example of theshape of a tapered pipe constituting a profile element pipe forhydraulic bulging according to the present invention.

FIGS. 6A and 6B are views illustrating the entire configuration of theprofile element pipes according to the present invention, andparticularly FIG. 6A shows an example in which parallel parts eachhaving a circular cross section are formed on both ends of the taperedpart having circular cross sections and FIG. 6B shows an example inwhich parallel parts each having a rectangular cross section are formedon both ends of the tapered part having rectangular cross sections.

FIGS. 7A and 7B are views illustrating the entire configuration of otherprofile element pipes according to the present invention, and showexamples having a transitional part between a parallel part on the largediameter side and a central tapered part.

FIGS. 8A to 8C are views explaining a method of producing the profileelement pipe according to the present invention, having a parallel parton the end portion of a large diameter side desired, where FIG. 8A is anentire perspective view, FIG. 8B is a developed view and FIG. 8C is aview showing a trapezoidal shape similar to the developed view shown inFIG. 8B.

FIGS. 9A to 9C are views showing another example of the profile elementpipe according to the present invention along with a shaft pressing toolused in the example, where FIG. 9A is an entire perspective view, FIG.9B is an enlarged view of the shaft pressing tool on the small diameterside and FIG. 9C is an enlarged view of the shaft pressing tool, whichalso serves as a small diameter side sealing tool used in the profileelement pipe.

FIGS. 10A to 10C are views showing shapes of end surfaces of the profileelement pipe of the present invention used in case where a smalldiameter side of a hydraulically bulged product has a rectangular crosssection, where FIG. 10A is a cross-sectional view of the pipe at aposition away from the pipe end on the small diameter side by δL+L0,FIG. 10C is a cross-sectional view of the end portion, and FIG. 10B is across-sectional view at an arbitrary intermediate position of the pipe.

FIGS. 11A to 11C are views showing shapes of end surfaces of the profileelement pipe of the present invention used in case where a largediameter side of a hydraulically bulged product has a rectangular crosssection, and particularly FIG. 11A is a cross-sectional view at aposition away from the pipe end on the large diameter side by δL′+L0′,FIG. 11C is a cross-sectional view of the end portion of the pipe, andFIG. 11B is a cross-sectional view at the arbitrary intermediateposition of the pipe.

FIGS. 12A to 12C are views illustrating cross-sectional shapes in casethat hydraulically bulged products have trapezoidal cross-sections.

FIGS. 13A to 13C are views illustrating cross-sectional shapes in casethat hydraulically bulged products have L-shaped cross-sections.

FIGS. 14A to 14C are views explaining a first example of a method of thepresent invention, and shows the case that a parallel part of an endportion of profile element pipe is formed prior to hydraulic bulging,where FIG. 14A is a cross-sectional view showing of a state of setting atapered pipe on dies, FIG. 14B is a cross-sectional view showing a statewhere the parallel part was formed before hydraulic bulging, and FIG.14C is a cross-sectional view showing a state where hydraulic bulginghas been completed.

FIGS. 15A to 15C are views showing relationships among an upper die onthe small diameter side, a shaft pressing tool also serving as a sealingtool and the end portion of profile element pipe, where FIGS. 15A to 15Care views elaborating on FIGS. 14A to 14C in terms of the dimensionalparameter.

FIGS. 16A to 16C are views showing relationships among an upper die onthe large diameter side, the shaft pressing tool also serving as asealing tool and the end portion of profile element pipe, where FIGS.16A to 16C are views elaborating on FIGS. 14A to 14C in terms of thedimensional parameter.

FIGS. 17A to 17C are views explaining a second example of the method ofthe present invention, and show a case where the parallel part of theend portion of profile element pipe is formed before setting the pipe ona die. Particularly, FIG. 17A is a cross-sectional view showing a stateof setting the profile element pipe on the die, FIG. 17B is across-sectional view showing a state before hydraulic bulging, and FIG.17C is a cross-sectional view showing a state after hydraulic bulging.

FIGS. 18A to 18C are views explaining a third example of the method ofthe present invention, and show another example of the case where theparallel part of the end portion of profile element pipe is formedbefore setting the pipe on the die. FIGS. 18A to 18C are the same as inthe case of FIGS. 17A to 17C.

FIGS. 19A to 19C are explanatory views showing a fourth example of themethod of the present invention, and show a configuration example inwhich an inner cavity of the parallel part at the large diameter side isaxially monotonously increased with reference to the pipe-end of thelarge diameter side. FIGS. 19A to 19C are the same as in the case ofFIG. 17A to 17C.

FIGS. 20A to 20D are views showing configuration examples of the shaftpressing tool, which is a component constituting the hydraulic bulgingdevice of the present invention, also serving as a sealing tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 5A to 5B are cross-sectional views showing an example of the shapeof tapered pipe constituting a profile element pipe of the presentinvention. A profile element pipe 11 for hydraulic bulging of thepresent invention is a profile element pipe to be provided for hydraulicbulging, has a peripheral length with an outer diameter graduallyincreasing or decreasing over axial length from one axial side towardthe other thereof and forms parallel parts 11 a, 11 b on at least onepipe-end (both pipe ends of a small diameter side and a large diameterside have parallel parts in the examples shown in FIGS. 5A and 5B).

In the profile element pipe for hydraulic bulging according to thepresent invention, it is desirable that lengths of the parallel parts 11a, 11 b are equal to or more than a total length of an amount of shaftpressing in the hydraulic bulging and a length necessary for sealing.

FIGS. 6A and 6B are views illustrating the entire configuration ofprofile element pipe according to the present invention, where FIG. 6Ashows an example in which parallel parts each having a circular crosssection are formed on both ends of tapered part having circular crosssections and FIG. 6B shows an example in which parallel parts having arectangular cross section are formed on both ends of the tapered parthaving rectangular cross sections.

Here, the example shown in FIG. 5A is elaborated by using FIGS. 6A and6B. FIG. 6A shows the rudimental basic form, in which parallel parts 11a and 11 b each having a circular cross-section are formed on both endsof tapered part having circular cross-sections.

FIG. 6B is an example in which parallel parts 11 a and 11 b each havinga rectangular cross-section are formed on both ends of tapered parthaving rectangular cross-sections. In the example shown in FIG. 6B, theparallel parts 11 a and 11 b have a cross-section shown in FIG. 10A tobe described later on a small diameter side 11 a and have across-section shown in FIG. 11C to be described later on a largediameter side 11 b over the entire length.

FIGS. 7A and 7B are views illustrating the entire configurations ofother profile element pipes according to the present invention, and showexamples having a transitional portion between a parallel part on thelarge diameter side and a central tapered part.

Next, the details of the example shown in FIG. 5B will be described byusing FIGS. 7A and 7B. FIG. 7A shows a view in which parallel parts 11 aand 11 b each having a circular cross section are formed on both ends ofa tapered part having a circular cross section and a transition portion11 c is provided between the large diameter side parallel part 11 b andthe central tapered part.

FIG. 7B shows a view in which parallel parts 11 a and 11 b each having arectangular cross section are provided on both ends of a tapered parthaving a rectangular cross section and a transition portion 11 c is alsoprovided between the large diameter side parallel part 11 b and thecentral tapered part.

In FIGS. 6B and 7B, although the parallel parts 11 a and 11 b formed onthe both ends, each of whose shapes is merely a rectangular crosssection, are shown, the shapes of the parallel parts 11 a and 11 b canbe a trapezoidal cross section as shown in FIGS. 12A to 12C to bedescribed later, an L-shaped cross-section as shown in FIGS. 13A to 13Cto be described later, a polygonal cross section not shown or the like.

In this case, if the final shape of a hydraulically bulged end surfaceis designed so that it agrees with a shape of an end surface of aproduct, the yield loss of material may be reduced, which is appreciatedvery much.

Further, in FIGS. 6B and 7B, although the central tapered part alsohaving rectangular cross sections is shown, the central part is notparticularly required to have rectangular cross sections and they may bea circular cross section as shown in FIGS. 6A and 7A. Alternatively, thecentral part may be subjected to bending or to pressing from upper andlower sides as well as from right and left sides so that a profileelement pipe can be facilitated to be inserted into a hydraulic bulgingdie.

FIGS. 8A to 8C are views explaining a method of producing the profileelement pipe according to the present invention having a parallel parton end portion of a large diameter side, and particularly FIG. 8A is anentire perspective view, FIG. 8B is a developed view and FIG. 8C is aview showing a trapezoidal shape similar to the developed view shown inFIG. 8B.

A method of producing a profile element pipe 11 according to the presentinvention having a parallel part 11 b on a large diameter side endportion of a tapered part having a circular cross-section as shown inFIG. 8A will be described as follows.

If a sheet having a shape shown in FIG. 8B is subjected to a simplebending and edges of a-b and a′-b′, edges of c-d and c′-d′, edges of b-eand c-e, and edges of b′-e and c′-e, are joined respectively, a profileelement pipe 11 having a parallel part 11 b on the large diameter sideend portion can be obtained as shown in FIG. 8A.

Meanwhile, in FIG. 8C, FIG. 8B is shown in addition by broken lines anda trapezoidal shape which is close to this is shown by solid lines.

As apparent from the comparison between the solid lines and brokenlines, when the trapezoid shown by solid lines in FIG. 8C is simplybent, a region b-c-e and a region b′-c′-e′ constitute a surplus. Namely,in a sheet bending process using a material of a trapezoidal shape, itis difficult to produce a profile element pipe having a parallel partlib at an end portion such as the profile element pipe 11 according tothe present invention.

Although the most simple method for producing the profile element pipeis a method comprising the process of simply bending a plate having adeveloped shape of a profile element pipe 11 according to the presentinvention to join with ends, other methods of producing profile elementpipes 11 according to the present invention having shapes shown in FIGS.6A and 6B and FIGS. 7A and 7B besides the above-mentioned method will bedescribed.

In case of the shape shown in FIG. 6A, the profile element pipe 11according to the present invention can be obtained by expanding an innerdiameter on the small diameter side and by reducing an outer diameter onthe large diameter side using “a merely tapered pipe” as a material, forexample. Further, in case of the shape shown in FIG. 6B, it can beobtained by crushing the central body part in addition to theabove-mentioned pre-forming.

In the description of the present invention, the term “a merely taperedpipe” means a material of a profile element pipe of the presentinvention and a tapered pipe in which a parallel part has not yet beenformed on one pipe end or both pipe ends.

In case of the shape shown in FIG. 7A, the profile element pipe 11according to the present invention can be obtained by expanding innerdiameters on the small diameter side and the large diameter side using“a merely tapered pipe” as a material, for example. Further, in case ofthe shape shown in FIG. 7B, it can be obtained by crushing the centralbody part in addition to the above-mentioned working process.

FIGS. 9A to 9C are views showing another example of the profile elementpipe according to the present invention and a shaft pressing tool usedin the example, where FIG. 9A is an entire perspective view, FIG. 9B isan enlarged view of the profile element pipe on the small diameter sideand FIG. 9C is an enlarged view of the shaft pressing tool, which alsoserves as a small diameter side sealing tool used in the shaft pressingtool. In the example shown in FIGS. 9A to 9C, an embodiment shown inFIG. 9A forms parallel parts 11 a and 11 b each having rectangular crosssection at both ends of a tapered part having rectangular crosssections.

Further, in the example shown in FIGS. 9A to 9C, rectangular crosssections having dimensions of substantially the same width and height asthose of the product are formed on a portion corresponding to Δl+L0 inthe small diameter side parallel part 11 a and on a portioncorresponding to Δl′+L0′ in the large diameter side parallel part 11 bin the merely tapered pipe.

Further, by determining a radius R of curvature of a corner part asdescribed later, extremely smooth pressing of a material can beperformed with dies 12 and 13 and shaft pressing tools 14 and 15 alsoserving as sealing tools in the hydraulic bulging, without generatingbucking or the like due to shaft pressing during hydraulic bulging.

FIGS. 10A to 10C are views showing shapes of end surfaces of the profileelement pipe of the present invention used in case that a small diameterside of a hydraulically bulged product has a rectangular cross section,where FIG. 10A shows a cross-sectional view at a position away from thepipe end on the small diameter side by Δl+L0, FIG. 10C shows across-sectional view of the end portion of the pipe, and FIG. 10B is across-sectional view at an arbitrary intermediate position of the pipe.

Namely, FIGS. 10A to 10C are views explaining a shape in each of crosssections of the small diameter side parallel part 11 a of a profileelement pipe of the present invention, and widths W0 and heights H0 incross sections of FIGS. 10A to 10C are substantially constant. Further,the radius R of curvatures of corner part is gradually changed byprevious forming.

As shown in FIGS. 10A to 10C, if a radius of curvature of corner part inthe small diameter side end portion is R0, a radius of curvature ofcorner part at a position away from the small diameter side pipe end byΔl+L0 in the axial direction is R1, and a radius of curvature of cornerpart at a position away from the small diameter side pipe end by X inthe axial direction is R(x), these radiuses have relationships of thefollowing expression (1).R0≧R(x)≧R1  (1)

In the examples shown in FIGS. 10A to 10C, the radiuses of curvatures offour corner parts in each cross section were set as the same. However,it is not necessary that they are set to be the same, and differentradiuses of curvatures at every corner part may be used.

More specifically, a peripheral length difference Δd(x) at the positionX away from a pipe end while setting a distance between both pipe-endsof a merely tapered pipe as a reference length, is obtained from thefollowing expression (2). In this case, D0 denotes an outer diameter onthe small diameter side, D0′ denotes an outer diameter on the largediameter side and LT denotes a length of the tapered pipe.Δd(x)=π·(D0′−D0)·X/LT  (2)

When a cross section of the end portion is pre-formed to a rectangularcross section having a width of W0 and a height of H0, the dimension ofa radius R(x) of curvature of the corner part is varied at axialpositions in accordance with the peripheral length difference δd(x) asshown in FIGS. 10A to 10C, so that a suitable shape of the pipe inpre-forming can be determined.

FIGS. 11A to 11C are views showing shapes of end surfaces of the profileelement pipe of the present invention used in case that a large diameterside of a hydraulically bulged product has a rectangular cross section,where FIG. 11A is a cross-sectional view of a pipe at the position awayfrom the pipe end on the large diameter side by Δl′+L0′, FIG. 11C is across-sectional view of the end portion of the pipe, and FIG. 11B is across-sectional view at the intermediate position of the pipe.

Namely, FIGS. 11A to 11C are views explaining a shape in each crosssection of the large diameter side parallel part 11 b of the profileelement pipe of the present invention, and widths W0′ and heights H0′ incross sections in FIGS. 11A to 11C are substantially constant. Further,the radius R′ of curvatures of corner part is gradually changed bypre-forming.

As shown in FIGS. 11A to 11C, if the radius of curvature of corner partin the large diameter side end portion is R0′, the radius of curvatureof corner part at a position away from the large diameter side endportion by Δl′+L0′ in the axial direction is set to R1′, and the radiusof curvature of corner part at a position away from the large diameterside end portion by X in the axial direction is R′(x), these radiuseshave relationships of the following expression (1′).R0′≦R′(x)≦R1′  (1′)

Specifically, the peripheral length difference δd(x) at a position Xaway from the edge of pipe end while setting a distance between bothpipe ends of a merely tapered pipe as a reference length, is obtainedfrom the following expression (2′). In this case, D0 denotes an outerdiameter on the small diameter side, D0′ denotes an outer diameter onthe large diameter side and LT denotes a length of the tapered pipe.Δd(x)=π·(D0′−D0)·X/LT  (2′)

When the cross section of the end portion is previously formed to therectangular cross section having a width of W0′ and a height of H0′, thedimension of the radius R′(x) of curvature of corner part is varied ataxial positions in accordance with the peripheral length differenceΔd(x) as shown in FIGS. 11A to 11C, so that the suitable shape of thepipe can be determined.

Although the case that a hydraulically bulged product has a rectangularcross section has been described as above, the profile element pipe ofthe present invention are not limited thereto. Alternatively, a combinedrectangular shape or a polygonal shape can be adopted and extremelystable shaft pressing can be performed during hydraulic bulging.

FIGS. 12A to 12C are views illustrating cross-sectional shapes in casethat hydraulically bulged products have trapezoidal cross-sections.FIGS. 13A to 13C are views illustrating cross-sectional shapes in casethat hydraulically bulged products have L-shaped cross-sections. FIGS.12 and 13 show examples of cross-sectional shapes of pre-formed pipes onthe large diameter side, wherein (a) is a cross sectional view at aposition away from the large diameter side pipe end by Δl′+L0′ in theaxial direction, (c) is a cross sectional view of the pipe end portion,and (b) is a cross sectional view at an intermediate positiontherebetween.

Next, a hydraulic bulging device according to the present invention anda hydraulic bulging method using the hydraulic bulging device will bedescribed with reference to drawings.

FIGS. 14A to 14C are views explaining a first example of a method of thepresent invention, and shows the case that a parallel part of an endportion of profile element pipe is formed prior to hydraulic bulging,where FIG. 14A is a cross-sectional view showing of a state of setting atapered pipe on a die, FIG. 14B is a cross-sectional view showing astate where the parallel part was formed before hydraulic bulging, andFIG. 14C is a cross-sectional view showing a state where hydraulicbulging has been completed.

FIGS. 15A to 15C are views showing relationships among an upper die onthe small diameter side, a shaft pressing tool also serving as a sealingtool and the end portion of the profile element pipe, where FIGS. 15A to15C are views elaborating on FIGS. 14A to 14C.

FIGS. 16A to 16C are views showing relationships among an upper die onthe large diameter side, the shaft pressing tool also serving as asealing tool and the end portion of the profile element pipe, whereFIGS. 16A to 16C are views elaborating on FIGS. 14A to 14C.

FIGS. 17A to 17C are views explaining a second example of the method ofthe present invention, and show the case that the parallel part of theend portion of the profile element pipe is formed before setting thepipe on a die. Particularly, FIG. 17A is a cross-sectional view showinga state of setting the profile element pipe on the die, FIG. 17B is across-sectional view showing a state before hydraulic bulging, and FIG.17C is a cross-sectional view showing a state after hydraulic bulging.

FIGS. 18A to 18C are views explaining a third example of the method ofthe present invention, and shows another example of the case that theparallel part of the end portion of profile element pipe is formedbefore setting the pipe on the die. Particularly, FIG. 18A is across-sectional view showing a state of setting the profile element pipeon the die, FIG. 18B is a cross-sectional view showing a state beforehydraulic bulging, and FIG. 18C is a cross-sectional view showing astate after hydraulic bulging.

The hydraulic bulging device of the present invention includes an upperdie 12 and a lower die 13 forming a cavity as shown in FIGS. 14, 17 and18, for example, and shaft pressing tools 14 and 15 which also servingas sealing tools, front end portions of which are inserted into therespective end portions of both dies 12 and 13. And the both dies 12 and13 as well as the shaft pressing tools 14 and 15 are constituted so thatboth ends of the profile element pipe 11 of the present invention aresandwiched and held by them.

Further, any one of the shaft pressing tools is provided with a fillinghole for working liquid, and an inner surface of at least one end side(both of the small diameter side and a large diameter side of the diehave parallel parts in examples shown in FIGS. 14, 17 and 18) and anouter surface of the shaft pressing tool corresponding to the innersurface of this end surface are provided with parallel parts 12 a, 12 b,13 a, 13 b, 14 a and 15 a, respectively.

The parallel parts 14 a and 15 a of the outer surfaces of the shaftpressing tools 14, 15 restrain the element pipe from the inner surfacesthereof during shaft pressing so that smooth deformation can be made.

In this hydraulic bulging device, if the amount of shaft pressing on thesmall diameter part side is defined as Δl, the amount of shaft pressingon the large diameter part side is defined as Δl′, the length requiredfor sealing the small diameter part side is defined as L0, the lengthrequired for sealing the large diameter part side is defined as L0′,lengths of the parallel parts 12 a, 12 b, 13 a and 13 b provided on aninner surface of at least one end side (both of the small diameter sideand the large diameter side of the die have parallel parts in examplesshown in FIGS. 14, 17 and 18) are desirably Δl+L0 or more in case of thesmall diameter side parallel parts, and Δl′+L0′ or more in case of thelarge diameter side parallel parts.

Also, lengths of the parallel parts 14 a and 15 a of the shaft pressingtools 14 and 15 corresponding to the parallel parts 12 a, 12 b, 13 a and13 b provided on dies 12, 13 are desirably Δl+L0 or more in case of thesmall diameter side parallel parts, and L0′ or more in case of the largediameter side parallel parts.

In the hydraulic bulging device of the present invention, a front endportion of the shaft pressing tool 14 (15) also serving as a sealingtool on the small diameter side (large diameter side) must be designedto be inserted into a small diameter side end portion (large diameterside end portion) of a merely tapered pipe PT as a material for theprofile element pipe 11 or a profile element pipe 11. At the same time,it is necessary that the parallel part 14 a (15 a) does not form a gapbetween a leading edge of the parallel part 14 a (15 a) and the innersurface of the profile element pipe 11 at the completion of shaftpressing.

Therefore, for example, as shown in FIGS. 14A to 14C, after a merelytapered pipe PT as a material for the profile element pipe 11 is set onthe upper die 12 and the lower die 13, if parallel parts 11 a and 11 bto be formed on the pipe end portions are formed in the upper die 12 andlower die 13 prior to hydraulic bulging, a shaft pressing tool alsoserving as a sealing tool must satisfy the following conditions A and B.

A. Shaft pressing tool 14 also serving as a sealing tool on the smalldiameter side (see FIG. 15)

A peripheral length SD0 of an envelope on the front end in which alocally concave portion was neglected satisfies the following expression(3).SD0≦(DO−2t/cos θ)×π  (3)

wherein

-   D0: Outer diameter of the small diameter end portion-   t: Wall thickness of profile element pipe 11-   θ=tan⁻¹ {(D0′−D0)/(2·LT)}-   LT: Length of tapered pipe PT-   D0′: Outer diameter of the large diameter end portion

B. Shaft pressing tool 15 also serving as a sealing tool on the largediameter side (see FIGS. 16A to 16C)

A peripheral length SD0′ of an envelope on the front end in which alocally concave portion was neglected satisfies the following expression(4).SD0′≦(DO′−2t/cos θ)×π  (4)

On the other hand, as shown in FIGS. 17A to 17C, when the parallel parts11 a and 11 b, which are formed on the end portions of the profileelement pipe 11, are previously formed before setting on the upper die12 and lower die 13, a shaft pressing tool which also serving a sealingtool satisfies the following conditions C and D.

C. Shaft pressing tool 14 also serving as a sealing tool on the smalldiameter side (see FIGS. 17A to 17C)

A peripheral length SD0 of a front end portion satisfies the followingexpression (5)SD0≦Peripheral length SD of the parallel part 14 a  (5)

D. Shaft pressing tool 15 which also serving as a sealing tool on thelarge diameter side (see FIGS. 17A to 17C)

A peripheral length SD0′ of a front end portion satisfies the followingexpression (6)SD0′≦Peripheral length SD′ of the parallel part 15 a  (6)

When a hydraulically bulged product 17 is formed by using the hydraulicbulging device according to the present invention, a merely tapered pipePT, which is a source material for the profile element pipe 11 of thepresent invention, is set in a pair of dies 12 and 13 for a hydraulicbulging device as shown in FIG. 14A, for example.

Next, prior to hydraulic bulging, shaft pressing tools 14 and 15 alsoserving as sealing tools are moved in the axial direction to formparallel parts 11 a and 11 b on an end or both ends of the tapered pipePT sandwiched by the dies 12, 13 and the shaft pressing tools 14, 15 asshown in FIG. 14B so that a profile element pipe 11 according to thepresent invention is formed.

At this time it is not necessary to synchronize the timing of shaftpressing of the profile element pipe 11 by the shaft pressing tools 14and 15. For example, when the shaft pressing tool 15 pushes the profileelement pipe 11 to some extent pushing by the shaft pressing tool 14 maybe started. Thus, the shaft pressing timing whereby the profile elementpipe 11 is held stably in the dies 12 and 13 may be selected.

In this case, if the dimensional design of the shaft pressing tools 14and 15 also serving as sealing tools and the dies 12, 13 is made withreference to the above-mentioned dimensions, the shaft pressing tools 14and 15 can be smoothly inserted into the tapered pipe TP.

In a state of FIG. 14B, as shown in FIGS. 15B and 16B, parallel parts 11a and 11 b having a length of L0 or more, preferably Δl+L0 or more onthe small diameter side, and having a length of L0′ or more on the largediameter side are formed on both ends of the tapered pipe PT so that theprofile element pipe 11 of the present invention can be obtained. Afterthat, an internal pressure is loaded on the profile element pipe 11 in astate where the sealing of working liquid is completely held.

Then, while the internal pressure of working liquid is increased, theshaft pressing tools 14 and 15 are moved in the axial direction to besubjected to hydraulic bulging. As a result as shown in FIG. 14C, ahydraulically bulged product 17 is formed by the method of the presentinvention.

Namely, in hydraulic bulging in which the profile element pipe 11 of thepresent invention is set on the hydraulic bulging device of the presentinvention, the shaft pressing becomes possible. As a result in thehydraulically bulged product 17 according to the method of the presentinvention, a larger pipe expansion ratio can be obtained than aconventional case.

Further, since an end surface of the hydraulically bulged product 17 isvertical with respect to the longitudinal axis as shown in FIG. 4B, thejoining or welding with the other part or member can be easily performedand the positioning of socket connection becomes possible.

FIGS. 19A to 19C are explanatory views showing a fourth example of themethod of the present invention, and shows a configuration example inwhich an inner cavity of the large diameter side parallel part isaxially monotonously increased with reference to an end of the largediameter of the pipe. Particularly, FIG. 19A is a cross-sectional viewshowing a state of setting a tapered pipe on the die, FIG. 19B is across-sectional view showing a state where a parallel part is formedbefore hydraulic bulging, and FIG. 19C is a cross-sectional view of astate after hydraulic bulging.

An example shown in FIGS. 19A to 19C has a different form from examplesshown in FIGS. 14, 17 and 18. That is the example shown in FIGS. 19A to19C also has parallel parts 12 a, 12 b, 13 a and 13 b on both endportions of both dies 12 and 13. However, a cavity inside the largediameter side parallel parts 12 b and 13 b of dies 12 and 13 ismonotonously decreased in the axial direction with reference to thelarge diameter end without locally narrowing a portion of the cavity asin the examples shown in FIG. 14 and the like.

Since the configuration example shown in FIG. 19A to 19C has small shaftpressing resistance and advantage over a metal flow, a formable range(pipe expansion limit) can be increased. Therefore, in the hydraulicbulging device of the present invention, a shape of the cavity formed inthe dies 12 and 13 is preferably designed to a shape shown in FIG. 19.

On the other hand, in parts of an automobile, cross-sectional shapes ofend portions of a product are similar to a rectangle, a combinedrectangle, and a shape of a polygon and the like which are intricateshapes in many cases.

As described above, FIGS. 18A to 18C are views showing an example of acase that the profile element pipe 11 of the present invention shown inFIG. 9A. In working process by using it, the profile element pipe 11shown in FIG. 9A is set in dies 12 and 13. FIG. 9B shows an enlargedview of the small diameter side profile element pipe 11 of the presentinvention. On the other hand, cross sectional shapes of the smalldiameter side parallel parts 11 a are as shown in FIGS. 10A to 10C.

With such profile element pipes 11 having cross sectional shapes,forming is performed using the shaft pressing tools 14 and 15 alsoserving as sealing tools, which is one example of the present invention.FIG. 9C shows the shaft pressing tool 14 also serving as a smalldiameter side sealing tool. The parallel part 14 a shown in FIG. 9C hasa width of W0−2t, a height of H0−2t, and a radius of curvature in acorner part of R1.

The shaft pressing tools 14 and 15 are pressed into end portions from astate shown in FIG. 18A, the forming of end portions of the profileelement pipe 11 is completed at the stage of FIG. 18B, so that theprofile element pipe 11 shown in FIG. 9B can be obtained while sealingof the working liquid has been fully held with the internal pressureloaded.

After that, while increasing the internal pressure of working liquid,the shaft pressing tools 14 and 15 are moved in the axial direction sothat a hydraulically bulged product 17 according to the method of thepresent invention can be obtained.

It is noted that the forming of the parallel parts 11 a and 11 b of pipeends, which is performed prior to hydraulic bulging may be carried outat pre-forming or at a stage prior to the pre-forming. The forming canbe implemented by existing working methods such as reducing, holeexpanding, swaging, spinning or a combination thereof.

FIGS. 20A to 20D are views showing configuration examples of the shaftpressing tool, which is a component constituting the hydraulic bulgingdevice, also serving as a sealing tool. FIG. 20A is a configurationexample of sealing the device with an end surface 14 b or 15 b, whichcomes into contact with end surfaces of the profile element pipe 11,FIG. 20B is also a configuration example in which a protrusion 14 c or15 c is provided on the end surface 14 b or 15 b respectively, FIG. 20Cis a configuration example in which steps 14 d and 15 d are provided onboundary parts between the parallel part 14 a or 15 a and the endsurface 14 b or 15 b, and FIG. 20D shows a configuration example inwhich an O ring 18 is provided on the parallel part 14 a or 15 a.

Any of the configuration examples shown in FIGS. 20A to 20D satisfiesthe relationships between the parallel parts 14 a, 15 a and a peripherallength of a front end shown by the expressions (3) to (6).

The above-mentioned examples show one concrete example of the presentinvention, and comparatively simple shapes of cavities for the dies 12and 13 are shown. However, a three-dimensional intricate shape of thecavity, which is represented by ordinary parts of an automobile, may beused.

Further, in the above-mentioned examples, shaft pressing applied fromboth a small diameter side and a large diameter side is shown. Accordingto the present invention, the shaft pressing tool has only to be adaptedto any one side, and the other side may be adapted to, for example, anon shaft pressing type as shown in FIG. 1, which is conventionallyapplied. Since effects of shaft pressing are varied by the shapes ofproducts, the scope of application of the present invention may bedetermined case by case.

Further, in the above-mentioned examples, although, as a material forthe profile element pipe 11, the case using a merely tapered pipe wasdescribed, a welded pipe by combining merely tapered pipes and a pipe incombination of a tapered pipe with a general straight pipe can also beapplied as source materials of the profile element pipes 11 of thepresent invention because each end portion of the pipe can be closelyapproximated to the relevant part of a merely tapered pipe.

INDUSTRIAL APPLICABILITY

A profile element pipe for hydraulic bulging according to the presentinvention has a peripheral length with an outer diameter graduallyincreasing or decreasing from one axial side toward the other thereofand has a parallel part formed on at least one end thereof. In ahydraulic bulging device and a hydraulic bulging method using theprofile element pipe, parallel parts are respectively provided on atleast one end portion inner surface of both an upper die and lower dieand an outer surface of a shaft pressing tool corresponding to said endportion inner surface. Then when the profile element pipe is set in adie, a bulging in which an internal pressure loading and a shaftpressing in the axial direction in combined manner can be performed.Thus, in the hydraulically bulged product, a larger pipe expansion ratiothan a conventional case can be obtained and a joining and socketconnection thereof to the other part can also be easily performed.Consequently, the hydraulically bulged product can be applied for use ofautomobiles and further other industrial machinery widely.

1. A profile element pipe for hydraulic bulging, wherein said profileelement pipe has a peripheral length with an outer diameter graduallyincreasing or decreasing from one axial side to the other thereof and aparallel part formed on at least one end thereof.
 2. The profile elementpipe for hydraulic bulging according to claim 1, wherein a length ofsaid parallel part is equal to, or more than, a total length of anamount of shaft pressing subjected in hydraulic bulging and a lengthnecessary for sealing during hydraulic bulging.
 3. The profile elementpipe for hydraulic bulging provided for producing a hydraulically bulgedproduct having a rectangular cross section or a polygonal cross sectionaccording to claim 2, wherein a radius R of curvature of a corner partin said parallel part is varied in accordance with a change in aperipheral length in which an outer diameter of the profile element pipeis gradually increased or decreased.
 4. A hydraulic bulging devicecharacterized by comprising: a pair of dies, and shaft pressing toolsalso serving as sealing tools, in which front end portions of the toolsare inserted into both ends of said dies, for holding said profileelement pipe according to claim 1, while sandwiching the profile elementpipe with said dies, wherein a filling hole for working liquid isprovided at any one of said shaft pressing tools and parallel parts areprovided on at least one end-portion inner surface of said dies and anouter surface of said shaft pressing tool corresponding to thisend-portion inner surface, respectively.
 5. A hydraulic bulging devicecharacterized by comprising: a pair of dies, and shaft pressing toolsalso serving as sealing tools, in which front end portions of the toolsare inserted into both ends of said dies, for holding said profileelement pipe according to claim 2 while sandwiching the profile elementpipe with said dies, wherein a filling hole for working liquid isprovided at any one of said shaft pressing tools and parallel parts areprovided on at least one end-portion inner surface of said dies and anouter surface of said shaft pressing tool corresponding to thisend-portion inner surface, respectively.
 6. A hydraulic bulging devicecharacterized by comprising: a pair of dies, and shaft pressing toolsalso serving as sealing tools, in which front end portions of the toolsare inserted into both ends of said dies, for holding said profileelement pipe according to claim 3, while sandwiching the profile elementpipe with said dies, wherein a filling hole for working liquid isprovided at any one of said shaft pressing tools and parallel parts areprovided on at least one end-portion inner surface of said dies and anouter surface of said shaft pressing tool corresponding to thisend-portion inner surface, respectively.
 7. The hydraulic bulging deviceaccording to claim 4, wherein when an amount of shaft pressing on thesmall diameter side is defined as δL, an amount of shaft pressing on thelarge diameter side of is defined as δL′, a length necessary for sealingon the small diameter side is defined as L0, and a length necessary forsealing on the large diameter side is defined as L0′, a length of aparallel part provided on the small diameter side of said die is δL+L0or more, a length of a parallel part provided on the large diameter sideof said die is δL′+L0′ or more, and a length of a parallel part providedon the small diameter side of the shaft pressing tool is δL+L0 or more,and a length of a parallel part provided on the large diameter side ofthe shaft pressing tool is L0′ or more.
 8. The hydraulic bulging deviceaccording to claim 5, wherein when an amount of shaft pressing on thesmall diameter side is defined as δL, an amount of shaft pressing on thelarge diameter side of is defined as δL′, a length necessary for sealingon the small diameter side is defined as L0, and a length necessary forsealing on the large diameter side is defined as L0′, a length of aparallel part provided on the small diameter side of said die is δL+L0or more, a length of a parallel part provided on the large diameter sideof said die is δL′+L0′ or more, and a length of a parallel part providedon the small diameter side of the shaft pressing tool is δL+L0 or more,and a length of a parallel part provided on the large diameter side ofthe shaft pressing tool is L0′ or more.
 9. The hydraulic bulging deviceaccording to claim 6, wherein when an amount of shaft pressing on thesmall diameter side is defined as δL, an amount of shaft pressing on thelarge diameter side of is defined as δL′, a length necessary for sealingon the small diameter side is defined as L0, and a length necessary forsealing on the large diameter side is defined as L0′, a length of aparallel part provided on the small diameter side of said die is δL+L0or more, a length of a parallel part provided on the large diameter sideof said die is δL′+L0′ or more, and a length of a parallel part providedon the small diameter side of the shaft pressing tool is δL+L0 or more,and a length of a parallel part provided on the large diameter side ofthe shaft pressing tool is L0′ or more.
 10. A hydraulic bulging method,wherein after producing a profile element pipe having a peripherallength with an outer diameter gradually increasing or decreasing fromone axial side toward the other thereof and having a parallel partformed on at least one end thereof by using a hydraulic bulging deviceaccording to claim 4, said profile element pipe is subjected tohydraulic bulging combined with an internal pressure loading and a shaftpressing.
 11. A hydraulic bulging method, wherein after producing aprofile element pipe having a peripheral length with an outer diametergradually increasing or decreasing from one axial side toward the otherthereof and having a parallel part formed on at least one end thereof byusing a hydraulic bulging device according to claim 5, said profileelement pipe is subjected to hydraulic bulging combined with an internalpressure loading and a shaft pressing.
 12. A hydraulic bulging method,wherein after producing a profile element pipe having a peripherallength with an outer diameter gradually increasing or decreasing fromone axial side toward the other thereof and having a parallel partformed on at least one end thereof by using a hydraulic bulging deviceaccording to claim 6, said profile element pipe is subjected tohydraulic bulging combined with an internal pressure loading and a shaftpressing.
 13. A bulged product wherein a profile element pipe having aperipheral length with an outer diameter gradually increasing ordecreasing from one axial side toward the other thereof and having aparallel part formed on at least one end thereof is set in a die of ahydraulic bulging device according to claim 4, and said profile elementpipe is subjected to hydraulic bulging combined with an internalpressure loading and a shaft pressing.
 14. A bulged product wherein aprofile element pipe having a peripheral length with an outer diametergradually increasing or decreasing from one axial side toward the otherthereof and having a parallel part formed on at least one end thereof isset in a die of a hydraulic bulging device according to claim 5, andsaid profile element pipe is subjected to hydraulic bulging combinedwith an internal pressure loading and a shaft pressing.
 15. A bulgedproduct wherein a profile element pipe having a peripheral length withan outer diameter gradually increasing or decreasing from one axial sidetoward the other thereof and having a parallel part formed on at leastone end thereof is set in a die of a hydraulic bulging device accordingto claim 6, and said profile element pipe is subjected to hydraulicbulging combined with an internal pressure loading and a shaft pressing.